boom end castings stuck

[Sanduskysailor]

The internal outhaul on my C&C 29-2 is jammed. I decide to remove the end fittings to fix it and possibly upgrade. I drilled out the stainless rivets and punched the mandrels. The fittings won't budge. Tried prying them off, a little hammer work- no way. Anybody got any good ideas? Thinking about tying a line through gooseneck area and pulling them off with a truck and hitch. Help! before I do something irretrievably wrong.

[deniseO30]

Make sure the pop rivets are actually drilled out. Many times the hollow part will remain even though it looks like it's gone. you can use the next size up pop rivets when you reassemble it.

There is probably that white residue that Alum gets over the years and it's working like cement keeping things from coming apart. Hope you have the boom of the boat! I had the same situation on my boom last year. I also could have made a months worth of birds nest soup! EW!

[14432]

Once you're sure the rivets are removed you need to deal with the oxidation. I've used penetrating oil with success. Squirt a little and the tap all around the fitting - especially where the rivets were. If the rivets were stainless, there's likely heavy oxidation around them. Squirt oil in the rivet holes and tap there as well. A hard "plastic" mallet is probably better than a steel hammer. It's easy to damage the fitting.

Some pics may yield some further advice.

[SVCarolena]

Aside from makeing sure all the rivets are out, as previously suggested, try soaking with PB Blaster penetrating oil for a few days then give it another shot. A deadblow hammer (rubber faced) may be useful, but remember that aluminum is easly bent and warped. Some heat could help, but could also ruin the finish on the boom.

[Sanduskysailor]

Thanks all for the advice. I am going to drill the holes a little larger just to be sure that all of the rivet is out. Next step I will soak with PB Blaster. Then the dead blow hammer. I have the boom off the boat since the boat is still on the hard awaiting some touch up Awl-Grip work.

[tommays]

Dont go a bit bigger as the NEW rivets will not WORK

[75R20]

You didn't mention what your boat is ,but if US built, the rivets are probably 3/16". Drill to that size and look closely to see if you got them. A little tapping of the cap and boom and it should be clear if you got all of them or not. If after soaking and tapping, if you still can't get it to move, you could always drill oversize to a #7 or 7/32" and tap the caps for 1/4" 20 bolts and then use stainless fasteners when you go back together. I prefer "button head allen" type fasteners for this.
Also look in the sail track for a "hidden" rivet or screw.
Best of luck
Kary
S/V Mariah
#49080

[Sanduskysailor]

Kary- You must have a 29-2 to know that. Mine is US built and yes those were 3/16" stainless rivets. I've been busy with work so I haven't proceeded. I like the idea of drilling a little oversize and tapping. I did drill the rivets in the sail track. Thanks for the advice. Sounds like you've done it before.

[75R20]

Originally Posted by Sanduskysailor

Kary- You must have a 29-2 to know that. Mine is US built and yes those were 3/16" stainless rivets. I've been busy with work so I haven't proceeded. I like the idea of drilling a little oversize and tapping. I did drill the rivets in the sail track. Thanks for the advice. Sounds like you've done it before.

Many....MANY times. Not on a 29-2 but a boom is ...... a boom.

I'd also recommend adding helicoils to the casting, so that the stainless bolts screw into stainless, if you decide to go that route.
Bolts and helicoils are also stronger, but do you really need it, if rivets held it for this many years. (in other words ...who cares)
The white oxidation cleans off easy enough, my boom used to drip for several hours into the cockpit after a good rain, before I took off the end casting and cleaned it, now it's clear in a matter of minutes.

You'd be surprised what people bring me to repair....... I'm not anymore.
Best of luck
Kary
S/V Mariah
#49080